System and method for manufacturing a top mount

ABSTRACT

A system and method for manufacturing a top mount for a vehicle suspension includes loading a top mount body, a journal, and a plurality of knurled studs into a lower die assembly. The lower die assembly includes a stationary die base, a floating die top, and a pusher shaft. A pusher head assembly applies a downward pressure to insert the knurled studs into the top mount body, while the pusher shaft substantially simultaneously applies an upward pressure to insert the journal into the top mount body. The floating die top and the pusher head assembly are raised in tandem to eject the top mount from the stationary die base. The floating die top and the pusher head assembly then retract so that the top mount can be removed from the system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/268,191, filed on May 2, 2014. The entire disclosure of the aboveapplication is hereby incorporated herein by reference.

FIELD

The present disclosure relates to top mounts for vehicle suspensionsand, more particularly, systems and methods for the assembly of topmounts.

BACKGROUND

A top mount couples a vehicle suspension strut to a support structure ofthe vehicle, and improves spring suspension and ride, and jounce andrebound control. Conventional upper strut mounts include at least oneresilient journal, usually formed from a rubber body with a metal core.The journal isolates and reduces transmission of road inputs to avehicle body.

Traditionally, assembly of the top mount has required multiple stationsin order to carry out the assembly operations. In a first station, thestuds are attached to the mount plate. The incomplete top mount assemblyis then removed from the first station and delivered to a secondstation, where the journal is disposed within the top mount body. Thismulti-station process is inefficient, as it requires additionalmachinery for both transport and assembly of the top mount. This processalso requires additional manpower, as two separate stations must bemaintained during the manufacturing process.

There is a continuing need for a system and method of assembling a topmount at a single station. Desirably, the system and method ofassembling the top mount is efficient and permits a rapid manufacture ofthe top mount by an individual operator.

SUMMARY

In concordance with the instant disclosure, a system and method formanufacturing a top mount in a single station, which is efficient andpermits a rapid manufacture of the top mount by an individual operator,has been surprisingly discovered.

In one embodiment, a system for manufacturing a top mount of a vehiclesuspension includes a floating die top configured to receive a top mountbody. The top mount body has a journal opening and a plurality of studholes. A plurality of knurled studs are removably disposed in the studholes. The floating die top has a primary opening and a plurality ofsecondary openings formed therethrough. The primary opening isconfigured to receive and align a journal adjacent the journal openingof the top mount body. The system further includes a stationary die basehaving a plurality of crimp blocks. The crimp blocks are disposed in thesecondary openings of the floating die top. The floating die top isslidably disposed over the crimp blocks. Each of the crimp blocks isconfigured to receive one of the knurled studs. A pusher head assemblyis configured to selectively move to and from a resting position and acrimping position. The pusher head assembly, when in the crimpingposition, contacts the top mount body to press the knurled studs intothe top mount body and to cause the crimp blocks of the stationary diebase to crimp the top mount body adjacent the knurled studs. The knurledstuds are thereby affixed to the top mount body. A pusher shaft isconfigured to selectively move to and from a retracted position and aninserting position through the stationary die base. The pusher shaft,when in the inserting position, contacts and advances the journal intothe journal opening of the top mount body. The journal is therebyaffixed to the top mount body.

In another embodiment, the pusher head assembly is coupled to a pusherhead assembly actuator configured to cause the pusher head assembly toselectively move to and from the resting position and the crimpingposition. The pusher shaft is coupled to a pusher shaft actuatorconfigured to cause the pusher shaft to move to and from the retractedposition and the inserting position. A floating die top actuator iscoupled to the floating die top. The floating die top actuator isconfigured to cause the floating die top to move a predetermineddistance in tandem with the pusher head assembly, as the pusher headassembly moves toward a resting position following a crimping operation.

The system may further include a controller configured to selectivelymove the pusher head assembly, the pusher shaft, and the floating dietop. A plurality of sensors including at least one of a force sensor anda position sensor are in communication with the controller and providefeedback on at least one of a force applied by the pusher head assemblyand a position of at least one of the floating die top and the pushershaft. An oiler assembly is disposed adjacent the floating die top, andis configured to receive the top mount body and lubricate the journalopening of the top mount body with a lubricant. The floating die top,the stationary die base, the pusher head assembly, the pusher shaft, thecontroller, the sensors, and the oiler assembly are mounted in a unitaryframe assembly.

In yet another embodiment of the instant disclosure, a method formanufacturing a top mount of a vehicle suspension is disclosed. Themethod includes providing a top mount body having a journal opening anda plurality of stud holes, a plurality of knurled studs, and a journal.The knurled studs are then inserted in the stud holes of the top mountbody. Substantially simultaneously, a pressure is applied to the topmount body to crimp the knurled studs in the stud holes of the top mountbody, and a separate pressure is applied to the journal to insert thejournal into the journal opening of the top mount body.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present disclosure, willbecome readily apparent to those skilled in the art from the followingdetailed description, particularly when considered in the light of thedrawings described hereafter.

FIG. 1A is an exploded front perspective view of a top mount accordingto one embodiment of the disclosure;

FIG. 1B is a partially exploded front perspective view of the top mountof FIG. 1A, with knurled studs disposed in stud holes of a top mountbody;

FIG. 1C is a front perspective view of the assembled top mount of FIG.1A, a journal shown disposed in a journal opening of a top mount body;

FIG. 2A is a front-left perspective view of a system for assembly of atop mount according to one embodiment of the disclosure, wherein thesystem is shown in a loading step where a journal, a top mount body, andknurled studs are disposed in the system;

FIG. 2B is a front-left perspective view of a system for assembly of atop mount according to one embodiment of the disclosure, wherein thesystem is shown in an assembly step where the knurled studs are affixedto the top mount body by crimping and the journal is advanced through ajournal opening of the top mount body;

FIG. 2C is a front-left perspective view of a system for assembly of atop mount according to one embodiment of the disclosure, wherein thesystem is shown in a stripping step where a pusher head assembly movesin tandem with the floating die top;

FIG. 2D is a front-left perspective view of a system for assembly of atop mount according to one embodiment of the disclosure, wherein thesystem is in an ejecting step wherein the assembled top mount ispresented in a convenient position for removal from the system;

FIG. 3A is an exploded front perspective view of the die assembly of thesystem of FIG. 2A;

FIG. 3B is cross-sectional perspective view of an oiler assembly takenalong section line 3B-3B in FIG. 2A;

FIG. 4A is a cross-sectional side elevational view of the system takenalong section line 4A-4A in FIG. 2A;

FIG. 4B is a cross-sectional side elevational view of the system takenalong section line 4B-4B in FIG. 2B;

FIG. 4C is a cross-sectional side elevational view of the system takenalong section line 4C-4C in FIG. 2C;

FIG. 4D is a cross-sectional side elevational view of the system takenalong section line 4D-4D in FIG. 2D;

FIG. 5 is a cross-sectional side elevational view taken through acentral axis of a lower die assembly of the system depicted in FIGS.2A-2D;

FIG. 6 is a cross-sectional side elevational view showing the floatingdie top cylinder of the lower die assembly of the system depicted inFIGS. 2A-2D; and

FIG. 7 is flow diagram illustrating the method for assembly of a topmount according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

The following detailed description and appended drawings describe andillustrate various embodiments of the invention. The description anddrawings serve to enable one skilled in the art to make and use theinvention, and are not intended to limit the scope of the invention inany manner. In respect of the methods disclosed, the steps presented areexemplary in nature, and thus, the order of the steps is not necessaryor critical.

FIGS. 1A-1C illustrate a top mount 2 in progressive states of assembly.In FIG. 1A, an exploded view of the component parts of the top mount 2prior to assembly is shown. The component parts of the top mount 2include a top mount body 4, a plurality of knurled studs 6, and aninsert body such as a journal 8. The illustrated top mount body 4 is ofan annular shape, and further comprises an opening such as a journalopening 10. The journal opening 10 has a semi-toroidal inner profile. Anannular mounting flange 12 extends radially outwardly from the journalopening 10. A plurality of stud holes 14 are disposed through themounting flange 12.

Although described hereinabove having a generally annular shape, itshould be appreciated that the top mount body 4 may be of any one of aplurality of different shapes, such as tri-ovular, elliptical, orpolygonal, for example. The mounting flange 12 may also include analignment feature 16 disposed therein for maintaining alignment of thestud holes 14 during assembly of the top mount 2.

The journal 8 is a resilient member having a journal body 18, typicallyformed of a polymeric material. The journal 8 is substantiallycylindrical in shape, having a cylindrical inner bore in which acylindrical rigid sleeve 20 is received, and a semi-toroidal outerprofile corresponding substantially to the inner profile of the journalopening 10. In particular embodiments, the rigid sleeve 20 may be formedfrom a metal such as aluminum. One of ordinary skill in the art mayselect suitable materials for the journal body 18 and the rigid sleeve20, as desired.

The knurled stud 6 includes a head 22, a threaded shank 24 extendingfrom the head 22, and a knurled shoulder 26 disposed intermediate thehead 22 and the threaded shank 24. An outer diameter of the knurledshoulder 26 is larger than an inner diameter of the respective studholes 14, and includes a plurality of protrusions extending radiallyoutwardly therefrom.

FIG. 1B illustrates the top mount 2 in a partly assembled state, whereinthe knurled studs 6 have been removably inserted into the stud holes 14.The knurled shoulders 26 are pressed into the respective stud holes 14,as shown, forming a frictional interference between the protrusions ofthe knurled shoulder 26 and the inner diameter of the stud holes 14 suchthat the knurled studs 6 are affixed within the stud holes 14. Inaddition to the frictional interference between the knurled shoulders 26and the inner diameter of the stud holes 14, a crimp is formed by thestud holes 14 around the knurled studs 6 to further secure the knurledstuds 6 within the stud holes 14.

In FIG. 1C, a fully assembled top mount 2 is illustrated, where thejournal 8 has been inserted through the journal opening 10 in the topmount body 4 such that the outer profile of the journal 8 is constrainedby the inner profile of the journal opening 10. Further movement of thejournal 8 within the journal opening 10 is thereby inhibited by thisconstraint.

One embodiment of a system according to the disclosure is illustrated inFIGS. 2A-6. As shown, the system is a press assembly 28 including apress frame 30, a die assembly 32, a plurality of sensors 34, acontroller 36, and an oiler assembly 38. The press frame 30 includes anupper press frame 40 and a press bed 42, each disposed between a pair ofuprights 44.

The die assembly 32 includes a lower die assembly 46, which is supportedby the press bed 42 of the press frame 30, and an upper die assembly 48,which depends from the upper press frame 40.

As shown in FIGS. 3A and 5, the lower die assembly 46 includes astationary die base 50. The exemplary stationary die base 50 is cuboidalin shape and includes an opposing top face 52 and bottom face 54. Aprimary bore 56 and a plurality of secondary bores 58 traverse thethickness of the stationary die base 50 from the top face 52 to thebottom face 54. The primary bore 56 is cylindrical in shape, having aninner diameter sufficient to receive the journal 8 therein, and extendsvertically through the stationary die base 50. The secondary bores 58are spaced about the primary bore 56. In the illustrated embodiment,there are three secondary bores 58 spaced equally about the primary bore56, but other quantities and spacings may be apparent to those ofordinary skill in the art.

A plurality of crimp blocks 60 protrude from the top face 52 of thestationary die base 50 and include fixture holes 62 therein forreceiving the threaded shank 24 of the knurled studs 6. In the exemplaryembodiment, the crimp blocks 60 are cylindrical in shape and arefrictionally received into corresponding bores formed in the stationarydie base 50. However, the crimp blocks 60 may be of other geometries,and may be joined to the stationary die base 50 using helical threads,bonding, or welding, as nonlimiting examples. The crimp blocks 60 andthe stationary die base 50 may also be made of a single unitary body, asdesired.

A floating die top 64 is further included in the lower dies assembly 46.The floating die top 64 is disposed adjacent to the top face 52 of thestationary die base 50. The floating die top 64 includes a primaryopening 66 and a plurality of secondary openings 68 spaced about theprimary opening 66. The primary opening 66 is axially aligned with theprimary bore 56 and the secondary openings 68 are axially aligned withcrimp blocks 60 of the stationary die base 50. Each of the secondarybores 58 of the floating die top 64 is appropriately sized to slidablyreceive a respective crimp block 60 therethrough, wherein when thefloating die top 64 abuts the top face 52 of stationary die base 50, thecrimp blocks 60 extend through, and protrude from, the floating die top64. An alignment dowel 70 may be included on the floating die top 64 forengaging the alignment feature 16 of the top mount body 4.

A pusher shaft 72 having an opposing first end 74 and second end 76 isdisposed through the primary bore 56 of the stationary die base 50. Thepusher shaft 72 is selectively positionable in a retracted position andin an inserting position. In the retracted position, the second end 76of the pusher shaft 72 is disposed substantially within the primary bore56 of the stationary die base 50. In the inserting position, the secondend 76 of the pusher shaft 72 is extended beyond the primary bore 56. Inthe illustrative embodiment, the first end 74 of the pusher shaft 72 isconnected to a pusher shaft actuator 78 beneath the stationary die base50. The pusher shaft actuator 78 can be any type of actuator capable ofproviding linear translation of the pusher shaft 72 through the primarybore 56 of the stationary die base 50, such as a pneumatic actuator, ahydraulic actuator, or a mechanical actuator, for example. In theillustrative embodiment, the pusher shaft actuator 78 is a pneumaticactuator such as a pneumatic stroker cylinder. The pusher shaft actuator78 is capable of providing a force sufficient to insert the journal 8into the journal opening 10 of the top mount body 4.

A center post 80 is disposed adjacent to the second end 76 of the pushershaft 72 and extends therefrom. The center post 80 includes mountingshank 82, a mandrel 84, and a collar 86. The mounting shank 82 of thecenter post 80 is attached to the second end 76 of the pusher shaft 72,such that the extension of the center post 80 from the second end 76 ofthe pusher shaft 72 is adjustable. In the illustrated embodiment of FIG.5, for example, the center post 80 has external helical threads forengaging internal helical threads of a bore in the second end 76 of thepusher shaft 72. An extension of the center post 80 is adjusted byrotating the center post 80 with respect to the pusher shaft 72. Thecollar 86 is disposed at an end of the mounting shank 82, intermediatethe mounting shank 82 and the mandrel 84. The mandrel 84 may becylindrical in shape, and extends from the collar 86 opposite themounting shank 82.

With renewed reference to FIG. 3A, an at least one floating die topcylinder 88 is included in the lower die assembly 46 and includes acylinder body 90 attached to the stationary die base 50 and a cylinderrod 92. The cylinder rod 92 extends through the secondary bore 58 of thestationary die base 50 and is coupled to the floating die top 64 via acoupling 93. The cylinder rod 92 is selectively positionable between afirst retracted position and a second extended position. The floatingdie top 64 abuts the stationary die base 50 when the cylinder rod 92 isin the retracted position. The floating die top 64 is spaced apart fromthe stationary die base 50 when the cylinder rod 92 is moved to theextended position. In the illustrative embodiment, three floating dietop cylinders 88 are included in the lower die assembly 46. It should beappreciated that any number of cylinders may be used within the scope ofthe present disclosure.

The upper die assembly 48 includes a pusher head assembly 94, as shownin FIG. 3A. The pusher head assembly 94 is configured to selectivelymove to and from a resting position, as shown in FIGS. 2A and 2D, and acrimping position, as shown in FIG. 2B.

The pusher head assembly 94 comprises a pusher head 96 having anopposing first end 98 and second end 100, a pusher head ring 102attached to the second end 100 of the pusher head 96, and a dead stop104. The pusher head ring 102 of the illustrative embodiment is annularin shape, and corresponds with the annular mounting flange 12 of the topmount body 4. It should be understood, however, that when a top mountbody 4 having a different shape is used, the pusher head ring 102 willhave a different corresponding shape. For example, for a tri-ovular topmount body 4, the corresponding pusher head ring 102 would be tri-ovularin shape.

The dead stop 104 of the pusher head assembly 94 is adjustably connectedto and spaced apart from the second end 100 of the pusher head 96. Thespacing between the dead stop 104 and the pusher head 96 is selectivelyadjustable to accommodate dimensional variations in journals 8 and topmount bodies 4. For example, the dead stop 104 may be adjusted to extendbeyond the pusher head ring 102 in one embodiment, and may be adjustedto be disposed within the pusher head ring 102 in another embodiment. Inthe illustrative embodiment, the dead stop 104 is concentric with theannular ring, such that the dead stop 104 is axially aligned with acenter axis of the journal opening 10 of the top mount body 4 when thepusher head assembly 94 is moved to the crimping position.

As further shown in FIG. 3A, a pusher head assembly actuator 106 iscoupled to the first end 98 of the pusher head 96. The pusher headassembly actuator 106 causes the pusher head assembly 94 to beselectively moved to and from the resting position and the crimpingposition. In the illustrative embodiment, the pusher head assemblyactuator 106 is a hydraulic actuator such as a hydraulic strokecylinder; however, other types of actuators including electromechanicaland pneumatic actuators, as nonlimiting examples, may also be used asthe pusher head assembly actuator 106 within the scope of thedisclosure.

More specifically, the pusher head assembly actuator 106 is capable ofexerting a downward force of fifty tons on the pusher head assembly 94when the pusher head assembly 94 is selectively moved to the crimpingposition. It has been surprisingly found that a downward force of fiftytons is sufficient to crimp the knurled studs 6 within the stud holes 14of the top mount body 4 without undesirably deforming a remainder of thetop mount body 4. However, other downward forces by the pusher headassembly actuator 106 may also be selected by one of ordinary skill inthe art, as desired.

The plurality of sensors 34 is in communication with the controller 36,and includes at least one position sensor and one force sensor, whichmay be disposed within the system in appropriate locations. The forcesensor provides feedback on a force applied by the pusher head assembly94. Another force sensor may provide feedback on a force applied by thepusher shaft 72. A position sensor may provide feedback on a position ofthe floating die top 64. Another position sensor may provide feedback ona position of the pusher shaft 72. Additional proximity sensors aredisposed on the lower die assembly 46 to provide feedback that thecomponent parts of the top mount 2 are present in the die assembly 32.Yet another sensor 34 may provide feedback on a received input from asystem operator, signaling that the system is ready for operation, e.g.,the top mount body 4 and the knurled studs 6 are in place and ready tobe processed. A skilled artisan may select other suitable types andnumbers of sensors in communication with the controller 36, as desired.

The controller 36 is in communication with the die assemblies and theplurality of sensors 34. As illustrated, the controller 36 is attachedto the press frame 30; however, the controller 36 may be independentlysituated from the press frame 30 in certain embodiments. The controller36 may include a user interface having a display and inputs, where theuser can adjust outputs communicated to the die assemblies from thecontroller 36, such as forces to be applied by the upper and lower dieassemblies, for example.

The oiler assembly 38, shown in cross-section in FIG. 3B, is positionedon the press bed 42 adjacent to the lower die assembly 46. The oilerassembly 38 is configured to receive the top mount body 4, and apply alubricant to the inner surface of the top mount body defining thejournal opening 10. The oiler assembly 38 includes an oil base 108having an oil delivery conduit 110 in fluid communication with a source112 of the lubricant. An oil drainage channel 114 is formed in an uppersurface of the oil base 108. A felt wick 116 is disposed atop the oilbase 108, and is in fluid communication with the oil delivery conduit110. The felt wick 116 is configured to contact the inner profile of thejournal opening 10 to apply the lubricant thereon.

In the illustrative embodiment of FIG. 3B, the felt wick 116 isfrustoconical and abuts a lubricant distributing weep cap 118, which hasa plurality of ports and is in fluid communication with the oil deliveryconduit 110. The oil drainage channel 114 includes an outlet 120 influid communication with the source 112 of the lubricant. Excess oil isreturned to the source 112 of the lubricant to be continuously cycledthrough the oiler assembly 38.

The present disclosure further includes a method 300 for manufacturingthe top mount 2 utilizing the press assembly 28 described herein, asshown in FIGS. 2A-7.

Referring to FIG. 7, the method 300 includes a loading step 302, anassembly step 304, a stripping step 306, and an ejecting step 308.Initially, the die assembly 32 is placed in a loading step 302, as shownin FIGS. 2A and 4A. The operator then provides the components of the topmount 2, including the top mount body 4, the plurality of studs 6, andthe journal 8. The journal 8 is first received and aligned within theprimary opening 66 of the floating die top 64, wherein the rigid sleeve20 of the journal 8 receives the mandrel 84 of the center post 80 tomaintain axial alignment of the journal 8 within the primary opening 66,and the journal 8 rests atop the collar 86 of the center post 80.

The operator next applies the journal opening 10 of the top mount body 4to the felt wick 116 of the oiler assembly 38 to provide a coating oflubricant to the journal opening 10. Subsequently, the lubricated topmount body 4 is placed atop the crimp blocks 60. The stud holes 14 ofthe top mount body 4 are aligned with the fixture holes 62 of the crimpblocks 60. The plurality of knurled studs 6 are then inserted throughthe stud holes 14 of the top mount body 4, wherein the threaded shank 24of each knurled stud 6 is received in the respective fixture holes 62 ofthe crimp blocks 60. The knurled shoulder 26 of the knurled studs 6abuts an upper face of the flange of the top mount body 4, adjacent eachof the stud holes 14.

With provision of the components complete, the plurality of sensors 34provide feedback to the controller 36 that the system is ready to beginan assembly step 304 including a crimping operation and a journalinsertion operation. In the assembly step 304, as shown in FIGS. 2B and4B, the knurled studs 6 and the journal 8 are substantiallysimultaneously affixed to the top mount body 4. During the assembly step304, the pusher head assembly 94 first moves from the resting position,as shown in FIG. 2A, to the crimping position shown in FIG. 2B, whereina downward force is applied to the pusher head assembly 94 by the pusherhead assembly actuator 106. In the crimping position, the pusher headring 102 contacts the heads 22 of the knurled studs 6. The pusher headassembly actuator 106 applies a predetermined downward force, forexample, of about fifty tons to the heads 22 of knurled studs 6,pressing the knurled shoulders 26 through the stud holes 14 to form aninterference fit between the protrusions of the knurled shoulders 26 andthe inner diameters of the stud holes 14. Once the knurled shoulders 26have been pressed through the stud holes 14, the predetermined downwardforce is transferred through the knurled studs 6 to the top mount body4, and causes the crimp blocks 60 to crimp the stud holes 14 around theknurled studs 6, further securing the knurled studs 6 in the crimpingoperation.

Once the controller 36 receives feedback from the force sensor 34 thatthe predetermined downward force has been applied and maintained, thepusher shaft 72 then moves from a retracted position, as shown in FIG.2A, to the inserting position shown in FIG. 2B, wherein the collar 86 ofthe center post 80 applies an upward force to the journal 8 sufficientto insert the journal 8 into the journal opening 10 in the journalinsertion operation. The dead stop 104 of the pusher head assembly 94 ispresent in an opposing end of the journal opening 10 to prevent thejournal 8 from being over-inserted beyond the journal opening 10.

With the assembly step 304 complete, the die assembly 32 progresses to astripping step 306. In the stripping step 306, the floating die top 64is advanced apart from the stationary die base 50 a predetermineddistance. As the floating die top 64 is advanced apart from thestationary die base 50, the knurled studs 6 of the top mount 2 arewithdrawn from the fixture holes 62 of the crimp blocks 60. Thepredetermined distance is any distance sufficient to withdraw thethreaded shank 24 of the knurled studs 6 from the crimp blocks 60, andis dependent on the length of the threaded shank 24. During thestripping step 306, the pusher head assembly 94 also moves in tandemwith the floating die top 64 to an intermediate position, as shown inFIGS. 2C and 4C, thereby sandwiching the top mount body 4 therebetween.

Subsequent to the stripping step 306, the press assembly 28 proceeds toan ejecting step 308 shown in FIGS. 2D and 4D. In the ejecting step 308,wherein the top mount 2 is presented to the operator for removal fromthe press assembly 28. With the knurled studs 6 mostly removed from thecrimp blocks 60, the pusher head assembly 94 is fully retracted to theresting position, and the floating die top 64 is returned to abut thetop face 52 of the stationary die base 50. Upon retraction of thefloating die top 64, an interference fit of a lower portion of theknurled studs 6 with the crimp blocks 60 causes the top mount 2 to besupported by the crimp blocks 60 in a convenient presentation forremoval from the press assembly 28. The operator may then return to theloading step 302, and the method 300 may be repeated to manufacturefurther top mounts 2.

Advantageously, the system and method for manufacturing the top mount 2of the present disclosure involves a single station or press assembly28. Likewise, the system and method is efficient and permits a rapidmanufacture of the top mount 2 by an individual operator, which hasheretofore not been possible with conventional top mount manufacturingsystems.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, can make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

What is claimed is:
 1. A method for manufacturing a top mount of avehicle suspension, the method comprising the steps of: providing a topmount body having an opening and a plurality of stud holes, a pluralityof knurled studs, and an insert body; inserting the knurled studs in thestud holes of the top mount body; and applying a pressure to the knurledstuds to press the knurled studs into top mount body and to crimp theknurled studs in the stud holes of the top mount body, and to insert theinsert body into the opening of the top mount body.
 2. The method ofclaim 1, further comprising the step of providing a system formanufacturing the top mount of the vehicle suspension, including: afloating die top configured to receive the top mount body, the floatingdie top having a primary opening and a plurality of secondary openingsformed therethrough, the primary opening configured to receive and alignthe insert body adjacent the opening of the top mount body; and astationary die base having a plurality of crimp blocks, the crimp blocksdisposed in the secondary openings of the floating die top, the floatingdie top slidably disposed over the crimp blocks, each of the crimpblocks configured to receive one of the knurled studs.
 3. The method ofclaim 2, wherein the floating die top is selectively positionablebetween a first position and a second position, the crimp blocks of thestationary die base extending through and protruding from the secondaryopenings of the floating die top when the floating die top is in thefirst position, and the crimp blocks spaced below the secondary openingsof the floating die top when the floating die top is in the secondposition.
 4. The method of claim 3, wherein the system further includes:a pusher head assembly configured to selectively move to and from aresting position and a crimping position, the pusher head assembly inthe crimping position contacting the knurled studs to press the knurledstuds into the top mount body and causing the crimp blocks of thestationary die base to crimp the top mount body adjacent the knurledstuds to thereby affix the knurled studs to the top mount body.
 5. Themethod of claim 4, wherein the floating die top moves a predetermineddistance in tandem with the pusher head assembly as the pusher headassembly moves toward the resting position following the applying of thepressure to the knurled studs to insert and crimp the knurled studs inthe stud holes of the top mount body, and the applying of the pressureto the insert body to insert the insert body into the opening of the topmount body.
 6. The method of claim 4, wherein the top mount of thevehicle suspension is presented assembled and ready for removal from thesystem by a returning of the floating die top to a beginning positionfollowing the moving of the floating die top the predetermine distancein tandem with the pusher head, the top mount where presented issupported by an interference fit of the knurled studs with the crimpblocks.
 7. A method for manufacturing a top mount of a vehiclesuspension, the method comprising the steps of: providing a system formanufacturing the top mount of the vehicle suspension, including: afloating die top configured to receive the top mount body, the floatingdie top having a primary opening and a plurality of secondary openingsformed therethrough, the primary opening configured to receive and alignan insert body adjacent the opening of the top mount body; a stationarydie base having a plurality of crimp blocks, the crimp blocks disposedin the secondary openings of the floating die top, the floating die topslidably disposed over the crimp blocks, each of the crimp blocksconfigured to receive one of the knurled studs a pusher head assemblyconfigured to selectively move to and from a resting position and acrimping position, the pusher head assembly in the crimping positioncontacting the knurled studs to press the knurled studs into the topmount body and causing the crimp blocks of the stationary die base tocrimp the top mount body adjacent the knurled studs to thereby affix theknurled studs to the top mount body.
 8. A method for manufacturing a topmount of a vehicle suspension, the method comprising the steps of:providing a top mount body having an opening and a plurality of studholes, a plurality of knurled studs, and an insert body all to a systemfor manufacturing the top mount; inserting the knurled studs in the studholes of the top mount body; and using the system to apply a pressure tothe knurled studs to press the knurled studs into top mount body and tocrimp the knurled studs in the stud holes of the top mount body, and toinsert the insert body into the opening of the top mount body; andejecting the top mount of the of the vehicle suspension from the systemfollowing the applying of the pressure to the knurled studs to insertand crimp the knurled studs in the stud holes of the top mount body, andthe applying of the pressure to the insert body to insert the insertbody into the opening of the top mount body.